High-performance thin-film composite polyamide membranes developed with green ultrasound-assisted interfacial polymerization

Photothermal-Assisted Interfacial Polymerization toward Microstructure Regulation of a Polyamide Membrane with Enhanced Separation Performance

A highly permeable thin-film composite (TFC) polyamide membrane with efficient salt rejection is valuable for numerous industrial processes. To achieve this objective, it is essential to innovate the membrane fabrication process to produce an ultrathin polyamide separation layer. In this study, a photothermal-assisted interfacial polymerization (IP) strategy was proposed to fabricate TFC polyamide membranes by incorporating carboxylated carbon nanotubes (CNTs) with exceptional photothermal properties. CNTs absorb solar energy and convert it into heat, significantly elevating the temperature in their microregions, thereby accelerating the reaction between m-phenylenediamine (MPD) and trimesoyl chloride (TMC) during the IP process. Exploiting the self-inhibition characteristics of IP, the preformed polyamide layer suppresses the subsequent diffusion of MPD into the reaction interface, resulting in the formation of an ultrathin polyamide layer. Consequently, the CNTs-modified polyamide membrane with photothermal assistance obtains a thickness of approximately 94 nm, significantly thinner than the control membrane (189 nm). Furthermore, it demonstrates a superior water flux of 54.4 L m-2 h-1, higher than that of the pristine TFC membrane without CNTs and the conventional CNTs-modified membrane, while maintaining a NaCl rejection of ∼96%. The photothermal-assisted IP strategy provides some inspiration for engineering high-performance polyamide membranes available in various advanced separations.

Interfacial Polymerization of Aromatic Polyamide Reverse Osmosis Membranes

Polyamide membranes are widely used in reverse osmosis (RO) water treatment, yet the mechanism of interfacial polymerization during membrane formation is not fully understood. In this work, we perform atomistic molecular dynamics simulations to explore the cross-linking of trimesoyl chloride (TMC) and m-phenylenediamine (MPD) monomers at the aqueous-organic interface. Our studies show that the solution interface provides a function of "concentration and dispersion" of monomers for cross-linking. The process starts with rapid cross-linking, followed by slower kinetics. Initially, amphiphilic MPD monomers diffuse in water and accumulate at the solution interface to interact with TMC monomers from the organic phase. As cross-linking progresses, a precross-linked thin film forms, reducing monomer diffusion and reaction rates. However, the structural flexibility of the amphiphilic film, influenced by interfacial fluctuations and mixed interactions with water and the organic solvent at the solution interface, promotes further cross-linking. The solubility of MPD and TMC monomers in different organic solvents (cyclohexane versus n-hexane) affects the cross-linking rate and surface homogeneity, leading to slight variations in the structure and size distribution of subnanopores. Our study of the interfacial polymerization process in explicit solvents is essential for understanding membrane formation in various solvents, which will be crucial for optimal polyamide membrane design.

Nanofoamed Polyamide Membranes: Mechanisms, Developments, and Environmental Implications

Thin film composite (TFC) polyamide membranes have been widely applied for environmental applications, such as desalination and water reuse. The separation performance of TFC polyamide membranes strongly depends on their nanovoid-containing roughness morphology. These nanovoids not only influence the effective filtration area of the polyamide film but also regulate the water transport pathways through the film. Although there have been ongoing debates on the formation mechanisms of nanovoids, a nanofoaming theory─stipulating the shaping of polyamide roughness morphology by nanobubbles of degassed CO2 and the vapor of volatile solvents─has gained much attention in recent years. In this review, we provide a comprehensive summary of the nanofoaming mechanism, including related fundamental principles and strategies to tailor nanovoid formation for improved membrane separation performance. The effects of nanovoids on the fouling behaviors of TFC membranes are also discussed. In addition, numerical models on the role of nanovoids in regulating the water transport pathways toward improved water permeance and antifouling ability are highlighted. The comprehensive summary on the nanofoaming mechanism in this review provides insightful guidelines for the future design and optimization of TFC polyamide membranes toward various environmental applications.

Enhancing Polysulfone Mixed-Matrix Membranes with Amine-Functionalized Graphene Oxide for Air Dehumidification and Water Treatment

Porous low-pressure membranes have been used as active membranes in water treatment and as support for thin-film composite membranes used in water desalination and gas separation applications. In this article, microfiltration polysulfone (PSf)mixed-matrix membranes (MMM) containing amine-functionalized graphene oxide (GO-NH₂) were fabricated via a phase inversion process and characterized using XPS, SEM, AFM, DMA, XRD, and contact angle measurements. The effect of GO-NH₂ concentration on membrane morphology, hydrophilicity, mechanical properties, and oil-water separation performance was analyzed. Significant enhancements in membrane hydrophilicity, porosity, mechanical properties, permeability, and selectivity were achieved at very low GO-NH₂ concentrations (0.05-0.2 wt.%). In particular, the water permeability of the membrane containing 0.2 wt.% GO-NH₂ was 92% higher than the pure PSf membrane, and the oil rejection reached 95.6% compared to 91.7% for the pure PSf membrane. The membrane stiffness was also increased by 98% compared to the pure PSf membrane. Importantly, the antifouling characteristics of the PSf-GO-NH₂ MMMs were significantly improved. When filtering 100 ppm bovine serum albumin (BSA) solution, the PSf-GO-NH₂ MMMs demonstrated a slower flux decline and an impressive flux recovery after washing. Notably, the control membrane showed a flux recovery of only 69%, while the membrane with 0.2 wt.% GO-NH₂ demonstrated an exceptional flux recovery of 88%. Furthermore, the membranes exhibited enhanced humidity removal performance, with a permeance increase from 13,710 to 16,408. These results indicate that the PSf-GO-NH₂ MMM is an excellent candidate for reliable oil-water separation and humidity control applications, with notable improvements in antifouling performance.

Enhancing the Antifouling Ability of a Polyamide Nanofiltration Membrane by Narrowing the Pore Size Distribution via One-Step Multiple Interfacial Polymerization

Application of nanofiltration membranes in industries still has to contend with membrane fouling that causes a significant loss of separation performance. Herein, an innovative approach to design antifouling membranes with a narrowed pore size distribution by interfacial polymerization (IP) assisted by silane coupling agents is reported. An aqueous solution of piperazine anhydrous (PIP) and γ-(2,3-epoxypropoxy) propytrimethoxysilane (KH560) is employed to perform IP with an organic solution of trimesoyl chloride and tetraethyl orthosilicate (TEOS) on a porous support. In accordance with the results of molecular dynamics and dissipative particle dynamics simulations, the reactive additive KH560 accelerates the diffusion rate of PIP to enrich at the reaction boundary. Moreover, the hydrolysis/condensation of KH560 and TEOS at the aqueous/organic interface forms an interpenetrating network with the polyamide network, which regulates the separation layer structure. The characterization results indicate that the polyamide-silica membrane has a denser, thicker, and uniform separation layer. The mean pore size of the polyamide-silica membrane and the traditional polyamide membrane is 0.62 and 0.74 nm, respectively, and these correspond to the geometric standard deviation (namely, pore size distribution) of 1.39 and 1.97, respectively. It is proved that the narrower pore size distribution endows the polyamide-silica membrane with stronger antifouling performance (flux decay ratio decreases from 18.4 to 3.8%). Such a membrane also has impressive long-term antifouling stability during cane molasses decolorization at a high temperature (50 °C). The outcomes of this study not only provide a novel one-step multiple IP strategy to prepare antifouling nanofiltration membranes but also emphasize the importance of pore size distribution in fouling control for various industrial liquid separations.

Vacuum-Assisted Interfacial Polymerization Technique for Enhanced Pervaporation Separation Performance of Thin-Film Composite Membranes

In this work, thin-film composite polyamide membranes were fabricated using triethylenetetramine (TETA) and trimesoyl chloride (TMC) following the vacuum-assisted interfacial polymerization (VAIP) method for the pervaporation (PV) dehydration of aqueous isopropanol (IPA) solution. The physical and chemical properties as well as separation performance of the TFCVAIP membranes were compared with the membrane prepared using the traditional interfacial polymerization (TIP) technique (TFCTIP). Characterization results showed that the TFCVAIP membrane had a higher crosslinking degree, higher surface roughness, and denser structure than the TFCTIP membrane. As a result, the TFCVAIP membrane exhibited a higher separation performance in 70 wt.% aqueous IPA solution at 25 °C with permeation flux of 1504 ± 169 g∙m-2∙h-1, water concentration in permeate of 99.26 ± 0.53 wt%, and separation factor of 314 (five times higher than TFCTIP). Moreover, the optimization of IP parameters, such as variation of TETA and TMC concentrations as well as polymerization time for the TFCVAIP membrane, was carried out. The optimum condition in fabricating the TFCVAIP membrane was 0.05 wt.% TETA, 0.1 wt% TMC, and 60 s polymerization time.

Naturally Extracted Hydrophobic Solvent and Self-Assembly in Interfacial Polymerization

Pharmaceutical, chemical, and food industries are actively implementing membrane nanofiltration modules in their processes to separate valuable products and recover solvents. Interfacial polymerization (IP) is the most widely used method to produce thin-film composite membranes for nanofiltration and reverse osmosis processes. Although membrane processes are considered green and environmentally friendly, membrane fabrication has still to be further developed in such direction. For instance, the emission of volatile solvents during membrane production in the industry has to be carefully controlled for health reasons. Greener solvents are being proposed for phase-separation membrane manufacture. For the IP organic phase, the proposition of greener alternatives is in an early stage. In this work, we demonstrate the preparation of a high-performing composite membrane employing zero vapor pressure and naturally extracted oleic acid as the IP organic phase. Its long hydrophobic chain ensures intrinsic low volatility and acid monomer dissolution, while the polar head induces a unique self-assembly structure during the film formation. Membranes prepared by this technique were selective for small molecules with a molecular weight cutoff of 650 g mol^-1 and a high permeance of ∼57 L m^-2 h^-1 bar^-1.

Nanovoid-Enhanced Thin-Film Composite Reverse Osmosis Membranes Using ZIF-67 Nanoparticles as a Sacrificial Template

In this work, nanovoid-enhanced thin-film composite (TFC) membranes have been successfully fabricated using ZIF-67 nanoparticles as the sacrificial template. By incorporating different amounts of ZIF-67 during interfacial polymerization, the resultant TFC membranes can have different degrees of nanovoids after self-degradation of ZIF-67 in water, consequently influencing their physiochemical properties and separation performance. Nanovoid structures endow the membranes with additional passages for water molecules. Thus, all the newly developed TFC membranes exhibit better separation performance for brackish water reverse osmosis (BWRO) desalination than the pristine TFC membrane. The membrane made from 0.1 wt % ZIF-67 shows a water permeance of 2.94 LMH bar^-1 and a salt rejection of 99.28% when being tested under BWRO at 20 bar. This water permeance is 53% higher than that of the pristine TFC membrane with the salt rejection well maintained.

Alleviation of Reverse Salt Leakage across Nanofiber Supported Thin-Film Composite Forward Osmosis Membrane via Heat-Curing in Hot Water

Electrospun nanofiber with interconnected porous structure has been studied as a promising support layer of polyamide (PA) thin-film composite (TFC) forward osmosis (FO) membrane. However, its rough surface with irregular pores is prone to the formation of a defective PA active layer after interfacial polymerization, which shows high reverse salt leakage in FO desalination. Heat-curing is beneficial for crosslinking and stabilization of the PA layer. In this work, a nanofiber-supported PA TFC membrane was conceived to be cured on a hot water surface with preserved phase interface for potential “defect repair”, which could be realized by supplementary interfacial polymerization of residual monomers during heat-curing. The resultant hot-water-curing FO membrane with a more uniform superhydrophilic and highly crosslinked PA layer exhibited much lower reverse salt flux (FO: 0.3 gMH, PRO: 0.8 gMH) than that of oven-curing FO membrane (FO: 2.3 gMH, PRO: 2.2 gMH) and achieved ∼4 times higher separation efficiency. It showed superior stability owing to mitigated reverse salt leakage and osmotic pressure loss, with its water flux decline lower than a quarter that of the oven-curing membrane. This study could provide new insight into the fine-tuning of nanofiber-supported TFC FO membrane for high-quality desalination via a proper selection of heat-curing methods.

A Critical Review on Thin-Film Nanocomposite Membranes with Interlayered Structure: Mechanisms, Recent Developments, and Environmental Applications

The separation properties of polyamide reverse osmosis and nanofiltration membranes, widely applied for desalination and water reuse, are constrained by the permeability-selectivity upper bound. Although thin-film nanocomposite (TFN) membranes incorporating nanomaterials exhibit enhanced water permeance, their rejection is only moderately improved or even impaired due to agglomeration of nanomaterials and formation of defects. A novel type of TFN membranes featuring an interlayer of nanomaterials (TFNi) has emerged in recent years. These novel TFNi membranes show extraordinary improvement in water flux (e.g., up to an order of magnitude enhancement) along with better selectivity. Such enhancements can be achieved by a wide selection of nanomaterials, ranging from nanoparticles, one-/two-dimensional materials, to interfacial coatings. The use of nanostructured interlayers not only improves the formation of polyamide rejection layers but also provides an optimized water transport path, which enables TFNi membranes to potentially overcome the longstanding trade-off between membrane permeability and selectivity. Furthermore, TFNi membranes can potentially enhance the removal of heavy metals and micropollutants, which is critical for many environmental applications. This review critically examines the recent developments of TFNi membranes and discusses the underlying mechanisms and design criteria. Their potential environmental applications are also highlighted.

Performance of chemically resistant polyurea reverse osmosis membrane in the treatment of highly alkaline industrial wastewater containing sodium aluminate

The goal of the present study is to treat industrial wastewater containing sodium aluminate using a chemically inert polyurea (PU) based thin film composite (TFC) reverse osmosis (RO) membrane to promote water reclamation and zero liquid discharge (ZLD). Pretreatment was carried out to reduce the pH of the effluent from 12.5 to 7.1. The TFC RO membrane was fabricated by coating PU on Polyethersulfone (PES) substrate by interfacial polymerization (IP). The surface and cross-sectional morphologies of the membrane were characterized using scanning electron microscopy (SEM). The indigenously synthesized membrane was effective in the removal of total dissolved solids (TDS), chemical oxygen demand (COD), colour and electrical conductivity. The experiments were conducted by varying the feed composition of the wastewater. The maximum water recovery and flux were found to be 74% and 73.9 L/m^2·h. RO process using PU membrane exhibited significant potential for cost effective, safe and pollution-free treatment of sodium aluminate industrial effluent.

Progress of Interfacial Polymerization Techniques for Polyamide Thin Film (Nano)Composite Membrane Fabrication: A Comprehensive Review

In this paper, we review various novel/modified interfacial polymerization (IP) techniques for the fabrication of polyamide (PA) thin film composite (TFC)/thin film nanocomposite (TFN) membranes in both pressure-driven and osmotically driven separation processes. Although conventional IP technique is the dominant technology for the fabrication of commercial nanofiltration (NF) and reverse osmosis (RO) membranes, it is plagued with issues of low membrane permeability, relatively thick PA layer and susceptibility to fouling, which limit the performance. Over the past decade, we have seen a significant growth in scientific publications related to the novel/modified IP techniques used in fabricating advanced PA-TFC/TFN membranes for various water applications. Novel/modified IP lab-scale studies have consistently, so far, yielded promising results compared to membranes made by conventional IP technique, in terms of better filtration efficiency (increased permeability without compensating solute rejection), improved chemical properties (crosslinking degree), reduced surface roughness and the perfect embedment of nanomaterials within selective layers. Furthermore, several new IP techniques can precisely control the thickness of the PA layer at sub-10 nm and significantly reduce the usage of chemicals. Despite the substantial improvements, these novel IP approaches have downsides that hinder their extensive implementation both at the lab-scale and in manufacturing environments. Herein, this review offers valuable insights into the development of effective IP techniques in the fabrication of TFC/TFN membrane for enhanced water separation.

Encapsulated Polyethyleneimine Enables Synchronous Nanostructure Construction and In Situ Functionalization of Nanofiltration Membranes

Highly permselective nanostructured membranes are desirable for the energy-efficient molecular sieving on the subnanometer scale. The nanostructure construction and charge functionalization of the membranes are generally carried out step by step through the conventional layer-by-layer coating strategy, which inevitably brings about a demanding contradiction between the permselective performance and process efficiency. For the first time, we report the concurrent construction of the well-defined molecular sieving architectures and tunable surface charges of nanofiltration membranes through precisely controlled release of the nanocapsule decorated polyethyleneimine and carbon dioxide. This novel strategy not only substantially shortens the fabrication process but also leads to impressive performance (permeance up to 37.4 L m^-2 h^-1 bar^-1 together with a rejection 98.7% for Janus Green B-511 Da) that outperforms most state-of-art nanofiltration membranes. This study unlocks new avenues to engineer next-generation molecular sieving materials simply, precisely, and cost efficiently.

Enhancing the Efficiency of a Forward Osmosis Membrane with a Polydopamine/Graphene Oxide Layer Prepared Via the Modified Molecular Layer-by-Layer Method

Water scarcity is one of the most critical problems that humans have to face. Working toward solving this problem, we have developed a thin-film composite (TFC) membrane using the modified molecular layer-by-layer (modified mLBL) method to fabricate polyamide (PA) active layers on different substrates. Besides, it has been found that graphene oxide (GO) contains abundant functional groups such as hydroxyl and epoxide groups, which are able to improve both the physical and chemical properties of the forward osmosis (FO) membrane. Thus, we have employed graphene oxide (GO) as the substrate and used the modified mLBL method to prepare active polydopamine/graphene oxide (PDA/GO) layers to enhance the water flux of the forward osmosis (FO) membrane. PDA/GO-coated layers could enhance the hydrophilic nature of the substrate and lower its surface roughness, which would facilitate the formation of the PA layer. Moreover, the PDA/GO coating can be applied to all substrates because of the high degree of adhesion of PDA to different substrates. In this study, the highly hydrophilic poly(vinylidene fluoride) membrane is superior in FO properties, with a water flux of 17.32 LMH and a reverse solute flux of 4.34 gMH. In addition, an excellent performance of 60.15 LMH and 14.88 gMH can be achieved when the pressure-retarded osmosis (PRO) test mode with a draw solution concentration of 2.0 M is used in the test. It shows that the membrane prepared using the novel method showed excellent FO performance, which has high potential in industrial applications such as desalination.

Intrinsic Nanoscale Structure of Thin Film Composite Polyamide Membranes: Connectivity, Defects, and Structure-Property Correlation

Transport of water, solutes, and contaminants through a thin film composite (TFC) membrane is governed by the intrinsic structure of its polyamide separation layer. In this work, we systematically characterized the nanoscale polyamide structure of four commercial TFC membranes to reveal the underlying structure-property relationship. For all the membranes, their polyamide layers have an intrinsic thickness in the range of 10-20 nm, which is an order of magnitude smaller than the more frequently reported apparent thickness of the roughness protuberances due to the ubiquitous presence of nanovoids within the rejection layers. Tracer filtration tests confirmed that these nanovoids are well connected to the pores in the substrates via the honeycomb-like opening of the backside of the polyamide layers such that the actual separation takes place at the frontside of the polyamide layer. Compared to SW30HR and BW30, loose membranes XLE and NF90 have thinner intrinsic thickness and greater effective filtration area (e.g., by the creation of secondary roughness features) for their polyamide layers, which correlates well to their significantly higher water permeability and lower salt rejection. With the aid of scanning electron microscopy, transmission electron microscopy, and tracer tests, the current study reveals the presence of nanosized defects in a polyamide film, which is possibly promoted by excessive interfacial degassing. The presence of such defects not only impairs the salt rejection but also has major implications for the removal of pathogens and micropollutants.

"Button and Buttonhole" Supramolecular Structure Enables the Self-Healing Behaviors of Functionalized Poly(ether sulfone) Membranes for Osmotic Power Generation

Osmotic power generation has emerged as an advanced technology toward water-energy nexus to tackle global water pollution. It provides a sustainable use of salinity gradient from water resources yet encounters major obstacles caused by pressure-retarded osmosis (PRO) membrane fouling. Although membranes with good antifouling properties are widely studied, their antifouling functions are readily lost when scratches or detachments occur through physical damage during operation and chemical degradation by water and corrosive foulants. Consequently, it is important to develop antifouling membranes with autonomous self-healing capabilities. Herein, self-healable functionalized poly(ether sulfone) (PES) antifouling membranes have been fabricated via the sequential conjugation of the zwitterionic random copolymer [poly(1-(1-(1-adamantylcarbonyloxy)methyl)-3-vinylimidazolium bromide-co-1-(3-sulfopropyl)-3-vinylimidazolium-co-vinylamine)] (P(ADVI-co-SBVI-co-VA), abbreviated as PASV copolymer) and linear cyclodextrin polymer (LPCD) on polydopamine-preactivated PES supports. The self-healing behaviors rely on the judiciously designed "button-and-buttonhole" supramolecular network. Specifically, β-cyclodextrins in LPCD and adamantines in PASV act as "buttonholes" and "buttons", respectively. Under physical and chemical damages, the β-cyclodextrin "buttonhole" may sacrificially detach from the adamantine "button" of PASV but then recap another adamantine to restore the protective function. The antifouling and self-healing traits of as-functionalized PES-g-PASV-LPCD membranes were demonstrated by the superior antiprotein behaviors and improved antimicrobial performances on both nonaged and aged samples. In the PRO process, the modified membranes were effective in mitigating organic fouling and exhibited higher power density (79% of the initial value) than the nonmodified ones (47% of the initial value) in municipal wastewater testing. The strategy for engineering inherently healable and antifouling membranes paves a new pathway for the development of sustainable membranes for osmotic power production.

Tailoring Polyamide Rejection Layer with Aqueous Carbonate Chemistry for Enhanced Membrane Separation: Mechanistic Insights, Chemistry-Structure-Property Relationship, and Environmental Implications

Surface roughness and the associated nanosized voids inside the roughness structures have great influence on the separation performance of thin film composite polyamide reverse osmosis (RO) membranes. Inspired by the recent findings that these voids are formed due to the degassing of CO₂ nanobubbles during interfacial polymerization, we systematically investigated the role of carbonate chemistry, particularly the solubility of CO₂, in the aqueous m-phenylenediamine (MPD) solution for the first time. "Ridge-and-valley" roughness features were obtained when the pH of the MPD solution was between the two acidity constants of the carbonate system (i.e., 6.3 ≤ pH ≤ 10.3), under which condition HCO₃^- dominates over the other carbonate species. Increasing pH over this range led to both increased water permeability and better rejection of various solutes, thanks to the simultaneously enhanced effective filtration area and cross-linking degree of the polyamide layer. Further increase of pH to 12.5 resulted in more disparate rejection results due to membrane hydrolysis: rejection of neural solutes (B and As(III)) was compromised whereas that of charged solutes (NaCl and As(V)) was maintained. The mechanistic insights gained in the current study reveal the critical need to design RO membranes directly for end applications based on first principles.